Miller Maxstar 150 STL Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

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Processes
Description
TIG (GTAW) Welding
Stick (SMAW) Welding
OM-2242 208 580AC
2012−10
Arc Welding Power Source
Maxstar 150 S, STL, And STH
With Auto-Linet
File: TIG (GTAW)
CE And Non-CE Models
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Mil_Thank 2009−09
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................
1-1. Symbol Usage 1.......................................................................
1-2. Arc Welding Hazards 1.................................................................
1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................
1-4. California Proposition 65 Warnings 4......................................................
1-5. Principal Safety Standards 4.............................................................
1-6. EMF Information 4.....................................................................
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................
2-1. Symboles utilisés 5.....................................................................
2-2. Dangers relatifs au soudage à l’arc 5......................................................
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....
2-4. Proposition californienne 65 Avertissements 8..............................................
2-5. Principales normes de sécurité 9.........................................................
2-6. Informations relatives aux CEM 9.........................................................
SECTION 3 − DEFINITIONS 11..................................................................
3-1. Additional Safety Symbols And Definitions 11................................................
3-2. Miscellaneous Symbols And Definitions 12..................................................
SECTION 4 − SPECIFICATIONS AND INSTALLATION 13...........................................
4-1. Important Information Regarding CE Products (Sold Within The EU) 13..........................
4-2. Serial Number And Rating Label Location 13................................................
4-3. Selecting A Location 13..................................................................
4-4. Specifications 14........................................................................
4-5. Duty Cycle And Overheating 14...........................................................
4-6. Volt-Ampere Curves 15..................................................................
4-7. Remote 6 Receptacle Information (STL And STH Models Only) 15..............................
4-8. Electrical Service Guide 16...............................................................
4-10. Connecting 115 VAC Input Power 17.......................................................
4-11. Connecting 1-Phase Input Power For 230 VAC 18............................................
4-12. Multi−Voltage Plug (MVP) Connection 20...................................................
SECTION 5 − OPERATION 21...................................................................
5-1. Front Panel Controls And Gas Connection 21................................................
5-2. Process Selection (STL Model Only) 21....................................................
5-3. Process Selection (STH Model Only) 22....................................................
5-4. Lift-Arc And TIG Impulse Start Procedures 22...............................................
5-5. Set-Up Procedure For The TIG Process And Restoring Factory Default Settings (STH Model Only) 24
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 26.......................................
6-1. Routine Maintenance 26.................................................................
6-2. Overload Protection 26..................................................................
6-3. Troubleshooting 27......................................................................
SECTION 7 − PARTS LIST 27...................................................................
SECTION 8 − ELECTRICAL DIAGRAM 28........................................................
OPTIONS AND ACCESSORIES
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
Maxstar 150 S 907351
Council Directives:
2006/95/EC Low Voltage
2004/108/EC Electromagnetic Compatibility
2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
IEC 609741:2005 Arc welding equipment – Part 1: Welding power sources
IEC 6097410:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,
arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz)
Signatory:
_____________________________________ ___________________________________________
David A. Werba Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
November 6, 2012
241517D
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
Maxstar 150 STH 907352
Council Directives:
2006/95/EC Low Voltage
2004/108/EC Electromagnetic Compatibility
2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
IEC 609741: 2005 Arc Welding Equipment – Part 1: Welding Power Sources
IEC 609743: 2007 Arc Welding Equipment – Part 3: Arc Striking and Stabilizing Devices
IEC 6097410: 2007 Arc Welding Equipment – Part 10: Electromagnetic Compatibility Requirements
EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,
arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz)
Signatory:
_____________________________________ ___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
November 6, 2012
241540D
OM-2242 Page 1
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shock
s
or severe burns. The electrode and work circuit i
s
electrically live whenever the output is on. The inpu
t
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automati
c
wire welding, the wire, wire reel, drive roll housing
,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperl
y
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install, ground, and operate this equipment according to
its Owners Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equip-
ment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-2242 Page 2
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
ARC RAYS can burn eyes and skin.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
WELDING can cause fire or explosion.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EM
F)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implante
d
Medical Devices should keep away.
Implanted Medical Device wearers should consult their docto
r
and the device manufacturer before going near arc welding, spo
t
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
CYLINDERS can explode if damaged.
Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
OM-2242 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
FLYING SPARKS can injure.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
Do not use welder to charge batteries or jum
p
start vehicles unless it has a battery chargin
g
feature designed for this purpose.
MOVING PARTS can injure.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
Read and follow all labels and the Owners
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owners
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-2242 Page 4
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga-
net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The Na-
tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk as-
sessment for welders. All welders should use the following procedures
in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
OM-2242 Page 9
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga-
net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The Na-
tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: Limiter par
exemple tout accès aux passants ou procéder à une évaluation des
risques individuels pour les soudeurs. Tous les soudeurs doivent
appliquer les procédures suivantes pour minimiser l’exposition aux
CEM provenant du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
A complete Parts List is available at www.MillerWelds.com
OM-2242 Page 11
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
A complete Parts List is available at www.MillerWelds.com
OM-2242 Page 12
Do not remove or paint over (cover) the label.
Safe20 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
3-2. Miscellaneous Symbols And Definitions
A
Amperes Voltage Input
S
Suitable For Areas
Of Increased
Shock Hazard
Shielded Metal Arc
Welding (SMAW)
V
Volts
Increase/Decrease
Of Quantity
Single Phase Static Frequency
Converter-Transformer-Rectifier
Output Negative Positive
Hz
Hertz
Gas Input High Temperature Direct Current Line Connection
Percent
X
Duty Cycle
U
1
Primary Voltage
U
2
Conventional Load
Voltage
Alternating
Current
U
0
Rated No Load
Voltage (Average)
I
1ma
x
Rated Maximum
Supply Current
I
2
Rated Welding
Current
I
1eff
Maximum Effective
Supply Current
Remote
Lift-Arc Start
(GTAW)
Gas Tungsten Arc
Welding (GTAW)
Process TIG (GTAW) Pulse
HF Impulse Start-
ing (GTAW)
On
Off
Look under unit for
label
A complete Parts List is available at www.MillerWelds.com
OM-2242 Page 13
SECTION 4 − SPECIFICATIONS AND INSTALLATION
4-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
B. Information On Electromagnetic Compatibility (EMC)
! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con-
ducted as well as radiated disturbances.
This equipment complies with IEC 61000-3-12.
ce-emc 4 2011-09
4-2. Serial Number And Rating Label Location
The serial number and rating information is located on the bottom of the machine. Use the rating labels to determine input power requirements and/or
rated output. CE model rating labels will also display the following symbols: CE, CCC, WEEE, and IEC 60974-1. For future reference, write serial
number in space provided on back cover of this manual.
4-3. Selecting A Location
803 351-D
1 Welding Power Source
Shoulder Strap
Use strap to lift unit.
! Do not move or operate unit
where it could tip.
! Installation must meet all
National and Local Codes
have only qualified persons
make this installation.
! Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
Locate unit near correct input pow-
er supply.
Position unit so air can circulate.
2
18 in.
(460 mm)
18 in. (460 mm)
Airflow Distance
Requirements
1
A complete Parts List is available at www.MillerWelds.com
OM-2242 Page 14
4-4. Specifications
Input Power
Single-Phase
AC
Rated Welding
Output
IP Rating
Welding
Amperage
Range
Max
OCV DC
(Uo)
Rated Peak
Starting
Voltage (Up)
Amperes In-
put At Rated
Load Output,
50/60Hz,
Single-Phase
KVA @
Duty
Cycle
KW
115 Volts Stick
15A
70A @ 22.8 Volts DC,
100% Duty Cycle
23 20 − 70A
90V
*12-16
**15 KV 17.4 2.0 1.9
115 Volts TIG
15A
100A @ 14 Volts DC,
100% Duty Cycle
23 5 − 100A
**15 KV 18.4 2.1 2.1
115 Volts Stick
20A
70A @ 22.8 Volts DC,
100% Duty Cycle
23
20 − 100A
90V
*12-16
**15 KV 17.4 2.0 1.9
100A @ 24.0 Volts DC,
35% Duty Cycle
23 **15 KV 26.4 3.0 3.0
115 Volts TIG
20A
100A @ 14.0 Volts DC,
100% Duty Cycle
23
5 − 150A
90V
*12-16
**15 KV 18.4 2.1 2.1
150A @ 16.0 Volts DC,
30% Duty Cycle
23 **15 KV 28.0 3.4 3.1
230 Volts Stic
k
100A @ 24 Volts DC,
100% Duty Cycle
23
20 − 150A
90V
*12-16
**15 KV 13.1 3.0 2.8
150A @ 26.0 Volts DC,
30% Duty Cycle
23 **15 KV 21.6 4.9 4.7
230 Volts TIG
100A @ 14.0 Volts DC,
100% Duty Cycle
23
5 − 150A
90V
*12-16
**15 KV 8.3 2.0 1.9
150A @ 16.0 Volts DC,
30% Duty Cycle
23 **15 KV 14.2 3.2 3.1
Weight 13.7 lb (6.2 Kg)
Dimensions H: 9 in. (229 mm), W: 5.5 in. (140 mm), L: 13.25 in. (337 mm)
*Sense Voltage For Stick And TIG Lift Arc
** Arc Striking Device Is Designed For Manual Guided Operations
4-5. Duty Cycle And Overheating
208 608-D
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, output stops, the
Overtemperature Light comes On,
and the cooling fan runs. Wait fif-
teen minutes for unit to cool. Re-
duce amperage or duty cycle be-
fore starting to weld again.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
0
50
100
150
200
250
10 100
STICK
(230V)
TIG/STICK
(115V 15A)
STICK
(115V 20A)
% DUTY CYCLE
OUTPUT AMPERES
50
TIG (115V 20A
& 230V)
A complete Parts List is available at www.MillerWelds.com
OM-2242 Page 15
4-6. Volt-Ampere Curves
Volt-ampere curves show minimum and maximum voltage and amperage output capabilities
of welding power source. Curves of other settings fall between curves shown.
208 604-B
TIG/Stick Max
TIG Min
Stick Min
Amperes
Volts
115 VAC Input
230 VAC Input
Amperes
Volts
TIG/Stick Max
Stick Min
TIG Min
100
80
60
40
20
0
0 50 100 150 200
100
80
60
40
20
0
0 50 100 150 200
4-7. Remote 6 Receptacle Information (STL And STH Models Only)
6
Socket Socket Information
15 VOLTS DC
OUTPUT
CONTACTOR
1 Contactor control +13.8 volts DC.
2 Contact closure to 1 completes contactor control
circuit and enables output when Lift-Arc TIG re-
mote is selected.
REMOTE
OUTPUT
CONTROL
3 Output to remote control; +10 volts DC output to
remote control.
4 0 to +10 volts DC input command signal from
remote control.
5 Remote control circuit common.
CHASSIS
6 Chassis common.
A complete Parts List is available at www.MillerWelds.com
OM-2242 Page 16
4-8. Electrical Service Guide
The Auto-Line circuitry in this unit automatically adapts the power source to the primary voltage being applied. Check input voltage available
at site. This unit can be connected to any input power between 120−230 VAC without removing the cover to relink the power source.
Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50/60 Hz Single
Phase
115 Volts AC
Input Voltage (V) 230
A 15 or 20
ampere individua
l
branch circuit
protected by
time-delay fuses
or circuit breaker
is required.
See Section 4-10
Input Amperes (A) At Rated Output 13.1
Max Recommended Standard Fuse Rating In Amperes
1
Time-Delay Fuses
2
15
Normal Operating Fuses
3
20
Min Input Conductor Size In AWG
4
14
Max Recommended Input Conductor Length In Feet (Meters)
91
(28)
Min Grounding Conductor Size In AWG
4
14
Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
4-9. Selecting Extension Cord (Use Shortest Cord Possible)
Single Phase AC
Input Voltage
Conductor Size − AWG (mm
2
)*
4 (21.2) 6 (13.3) 8 (8.4) 10 (5.3) 12 (3.3)
Maximum Allowable Cord Length in ft (m)
115 160 (49) 107 (33) 71 (22) 47 (14) 29 (9)
230 471 (144) 321 (98) 215 (66) 146 (45) 90 (27)
*Conductor size is based on maximum 3% voltage drop
A complete Parts List is available at www.MillerWelds.com
OM-2242 Page 17
! Do not move or operate
unit where it could tip.
! Installation must meet all
National and Local Codes
have only qualified
persons make this
installation.
! Special installation may be
required where gasoline or
volatile liquids are present
see NEC Article 511 or
CEC Section 20.
The Auto-Line circuitry in this
unit automatically links the
power source to the primary
voltage being applied, either
115 or 230 VAC.
NOTICE − Do Not cut off power
cord connector and rewire. The
power cord connector and plugs
will work with standard NEMA re-
ceptacles. Modifying power cord,
connector, and plugs will void
product warranty.
For 115 volts AC input power, a
15 or 20 ampere individual
branch circuit protected by
time-delay fuses or circuit
breaker is required. For 230 volts
AC input power, see Section
4-11.
1 Power Cord
2 Multi-Voltage Plug And
Power Cord Connector
− NEMA Type 5−15P
3 Receptacle − NEMA Type
5−15R (Customer Supplied)
For multi−voltage plug connec-
tions, see Section 4-12.
Connect plug to receptacle.
Ref. 803 351-D
4-10. Connecting 115 VAC Input Power
3
2
1
A complete Parts List is available at www.MillerWelds.com
OM-2242 Page 18
4-11. Connecting 1-Phase Input Power For 230 VAC
803 766-C / Ref. 802 443-A
4
3
L1
L2
1
=GND/PE Earth Ground
2
1
5
6
7
Tools Needed:
L1
L2
230 VAC, 1
8
9
A complete Parts List is available at www.MillerWelds.com
OM-2242 Page 19
4-11. Connecting 1-Phase Input Power For 230 VAC (Continued)
! Installation must meet all National
and Local Codes − have only
qualified persons make this
installation.
! Disconnect and lockout/tagout input
power before connecting input
conductors from unit.
! Always connect green or green/yellow
conductor to supply grounding termi-
nal first, and never to a line terminal.
See rating label on unit and check input volt-
age available at site.
The Auto-Line circuitry in this unit auto-
matically links the power source to the
primary voltage being applied, either 115
or 230 VAC.
NOTICE − Do Not cut off power cord connec-
tor and rewire. The power cord connector and
plugs will work with standard NEMA recep-
tacles. Modifying power cord, connector, and
plugs will void product warranty.
1 Black And White Input Conductor (L1
And L2)
2 Green Or Green/Yellow Grounding
Conductor
3 Input Power Cord.
4 Disconnect Device (switch shown in the
OFF position)
5 Disconnect Device Grounding Terminal
6 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to dis-
connect device line terminals.
7 Over-Current Protection
Select type and size of over-current
protection using Section 4-8 (fused
disconnect switch shown).
8 Receptacle (NEMA 6-50R)
Customer Supplied
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
9 Multi-Voltage Plug And Power Cord
Connector (NEMA 6-50P Plug Shown)
For multi−voltage plug connections, see Sec-
tion 4-12.
Connect plug to receptacle.
A complete Parts List is available at www.MillerWelds.com
OM-2242 Page 20
4-12. Multi−Voltage Plug (MVP) Connection
Selecting Plug
1 Power Cord Connector From
Welding Power Source
Select plug for power supply receptacle
available at site. Not all plugs shown are
provided as standard with unit.
2 Plug − NEMA Type 5−15P
3 Receptacle − NEMA Type 5−15R
(Customer Supplied)
4 Plug − NEMA Type 5−20P (Optional)
5 Receptacle − NEMA Type 5−20R
(Customer Supplied)
6 Plug − NEMA Type 6−50P
7 Receptacle − NEMA Type 6−50R
(Customer Supplied)
! Follow electrical service guide for
230 VAC in Section 4-8. Do not use
plug rating to size branch circuit
protection.
Connecting Plug To Power Cord
Align arrow on plug with arrow on power
cord connector. Push together.
Tighten threaded collar. As threaded collar
is tightened, push plug onto adapter until
collar is completely tight.
Connect plug to receptacle.
MVP Plug1 2010−10 / Ref. 803 812-C
! Do not cut off power cord connec-
tor and rewire. The power cord
connector and plugs will work
with standard NEMA receptacles.
Modifying power cord, connector,
and plugs will void product war-
ranty.
3
2
7
4
5
6
1
Selecting Plug
Connecting Plug To Power Cord
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Miller Maxstar 150 STL Owner's manual

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Welding System
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Owner's manual
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